FlexiArch

A Cost Effective Replacement for Short

and Medium Span Bridges

1
Abhey Gupta, Project Manager, Macrete Ireland Limited
 Contents

Company Introduction
Basic Concept
Background
Origin of Concept
Development of FlexiArch
Experimental validation: Stability, Strength
Analytical validation
Applications of FlexiArch
Experience to date
Future developments
Lessons Learned
Concluding remarks
2
Company Introduction
3
 Macrete Ireland Limited
Mission
To be recognised as a major provider
of precast concrete technology,
products, services and solutions and
to serve our customers regionally,
nationally and internationally.

4
 Diverse Markets

Network Rail
Water Companies
Highways Agencies
Sea Defence
Marine
Agriculture

5
MK Dons Stadium

6
Great Yarmouth Harbour

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Cycle Path Tunnel, Cumbria

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Preston Flood Relief

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Boscombe Pier Installation

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South Coast Sea Defence

11
FlexiArch Concept
12
 Origin of Concept FlexiArch

Historic Methods

EEC directive 85/3 dated 1999

The introduction of 40T commercial vehicle

BD 57/01 and BA 57/01; Design for Durability

(UK Highway Agency)
No steel / High durability

13
 Historical Method

Traditional masonry arch

bridges are aesthetic, durable
and strong

However they require

centring and extensive
formwork, which is expensive
and time consuming 14
 FlexiArch Historically New

FlexiArch is a modular, unreinforced, precast, concrete

arch bridge system, which is based on the same principles
as traditional stone masonry built arch bridges dating from
Roman times but without the stone mason.

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 Method of Construction

Top layer cast over voussoirs

Polymeric reinforcement

Precast concrete blocks

Construction bed

Casting Voussoirs Precast Voussoirs Polymeric Reinforcement

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1st Prototype - Paragrid Affixed

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Screed with Crack Inducers

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Lifting of Prototype

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Lifting of Prototype

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Lifting of Prototype

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Setting in Place

22
 Development of FlexiArch

Is there a market?
Over 90,000 arch bridges in UK
Many need repair, strengthening or
replacement

Solution may be simple but required:

12 years of laboratory research leading to a
patent
5 years of R&D within Macrete Ireland Limited
Attention to detail/quality but cost competitive

23
FlexiArch Testing
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 Experimental Validation

Model tests at QUB

Third scale: 5 x 2, 10 x 2, 15 x 3. ( metres )
Conventional backfill vs Concrete
Loading to ultimate

Full scale tests at Macrete Ltd

Stability: 5 x 2, 10 x 2, 15 x 3. ( metres )
Strength: 5 x 2, 10 x 2, 15 x 3. Max 74t
(concrete)

Full scale tests at actual bridge site

(Tievenameena Bridge, NI)

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3rd Scale Single FlexiArch Unit
Test at QUB

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Full Scale Single FlexiArch Unit
Test at Macrete

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Instrumentation of Full Scale Single
FlexiArch Unit Test at Macrete

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Full Scale FlexiArch Bridge
Test at Macrete

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Full Scale Cantilever Test to Verify
Paragrid Creep During Lifting

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 Real World Test Site
Tievenameena Bridge

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Instrumentation for Load Test

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Load Test at Site

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 Analytical Validation

A range of methods utilised including:

Reynolds / Mexe
ARCHIE
RING
Spreadsheet methods
Variable depth beam
Equivalent grillage for Skew
Non-linear Finite Element Analysis

34
 Analysis using ARCHIE software

Loading

Arch unit

Thrust line

Passive Backing
pressure material

35
Stress Distribution Using FEA

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 Findings

Arch ring has acceptable strain levels during lifting

Arch ring is stable under concrete or granular backfill

The strength of the arch ring is enhanced with backfill in

place

Good correlation between test results and the design

softwares output.

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FlexiArch Case Study
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Case Study - Devon

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The Site

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Foundation

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Arch delivered

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Lift Stage 1

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Lift Stage 2

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Hanging free

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Placed

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Packed

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Continuing

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Spandrels

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Spandrel Walls Placed

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Ready for concrete fill

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Concrete Fill Completed

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Brick Cladding

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Road Finish

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Completed Bridge

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 Advantages of FlexiArch

Flat pack transportation

Factory controlled production providing high quality finish
to all elements
All structural elements are unreinforced concrete,
meaning reduced future maintenance costs (projected
120 years design life)
Reduced number of on site operatives
Watercourse / track not disturbed during construction
Modular construction on site reducing construction time
Can be cladded to suit clients requirements
Cost competitive with RC alternatives

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FlexiArch Projects
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Access Bridge, FP McCann

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Celbridge Co. Kildare

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Footbridge, Newtonabbey

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Gloucestershire

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Tievenameena Bridge

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Merthyr Tydfil

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Bentely, Yorkshire

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 In Production

Shropshire, Sheinton Bridge - 13.7m Span

Longest commercial FlexiArch to date

65
 Out to Tender
Jacobs - Clough Brook Culvert
62 FlexiArch units

66
 Preliminary Design
Sligo N17
Widening MultiSpan Masonry Arch Bridge

67
Anticipated FlexiArch Developments
and Lessons Learned 68
Road Widening

Flexi Arch

Road Widening
Tunnels

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 Increase range of spans

Initially 3m to 10m
Successfully constructed 15m x 3m
Consider 20m plus achievable if:
Adequate crane capacity
Suitable transport

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Skew FlexiArch

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Skew Model

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Setting Out Template for Full Scale

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Aligning Vouissoirs

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Initial Shape During Lifting

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Skew FlexiArch

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Trial Assembly

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Trial Assembly

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Spandrel Attached

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Double Radius FlexiArch

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 Geometry Development

Double Radius Arches being developed to fit

Network Rail Profiles

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Double Radius FlexiArch

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 Recent Technological Advances

1. Modification of footing blocks

No dowel
Upstand provided in insitu
abutment instead, full height or to
height of footing unit

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 Recent Technological Advances

2. Modification of fixing of spandrel wall

No longer use tie bars
Stainless steel brackets provided for fixing

85
 Recent Technological Advances

3. Revised Concrete Infill - Lower strength infill

is being used with good concrete slab on top

86
 Recent Technological Advances

4. Provision for Stone Cladding

Original Concrete Finish Brick Cladding

Rib slots cast-in 87

 Recent Technological Advances

5. Corbels to be colour matched to stone where

desired for aesthetics

88
 Concluding Remarks
Capital vs Life Cycle vs Whole Life Costs

Cost

Repair

40 years 80 years 120 years

Time 89
 Concluding Remarks

Precise arch geometry without centring

Assembly of precast bridge units << 1 day
Minimal disruption to river / track
Comparable initial capital cost
Very durable, no corrodible reinforcement
Minimum total life cycle cost
FlexiArch can greatly enhance use of short /
medium span arch bridges
Ideal for retrofit and strengthening 90
The installation process was straightforward,
went to plan, and was quick.
Andrew Broad, General Works Manager, Dean & Dyball Civil Engineering
(Escot Estate FlexiArch Installation two bridges)
The FlexiArch was chosen for the Newtownabbey
cycle path project because of its aesthetic
suitability, economic deployment, sustainable
construction and consideration for environmental
issues such as avoidance of disturbance to the
river bed.
Neil Luney, Rural Project Officer, Newtownabbey Borough Council
(National Cycle Path development on rural land three bridges)
The FlexiArch system and installation process
completely suited this location for replacement of
an old arch bridge. There are definitely other
locations within the county where this will be
seriously considered as an appropriate solution
for bridge replacement.
Mladen Dragojlovic, Gloucestershire County Council
(County lane river crossing bridge replacement)
The procurement, delivery and erection of the
precast units was extremely efficient. Merthyr
Tydfil CBC and the general public have
expressed extreme satisfaction with the
completed structure.
Mark Robinson, Merthyr Tydfil County Borough Council
(River Taff Corridor Improvements one bridge)
Any Questions?

Thank You

Abhey Gupta
Project Manager
07792124084
95
Email: abhey@macrete.com